Composite Energy Absorber Geometry for EV Side-Impact Protection
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Solution Overview
Problem
Existing energy absorbers in electric vehicles fail to efficiently manage peak loads and intrusion distances during side impact events, leading to potential damage to the rechargeable energy storage system (RESS) and increased reaction forces.
Innovation Solution
A composite energy absorber with a geometric pattern made of reinforcing fibers and polymer matrix, integrated into the rocker section and RESS rail, which absorbs energy by crushing uniformly along its length, reducing peak loads and intrusion distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional energy absorbers are used in side impact events, then the structure can absorb some impact energy, but the peak loads and intrusion distances are not sufficiently reduced, leading to potential damage to the RESS
Solution Approach 1:
The energy absorber is divided into multiple identical cells arranged in series along its length. Each cell contains a geometric pattern of struts that deform independently during impact, creating multiple progressive collapse zones. This segmentation allows the total impact energy to be distributed across multiple smaller deformation events rather than one large peak load, reducing the maximum force transmitted to the RESS while maintaining reliable energy absorption.
Solution Approach 2:
The struts within each cell are designed with curved or geometric patterns (such as sinusoidal, elliptical, or polygonal cross-sections) rather than straight rigid members. These curved geometries enable progressive buckling and controlled deformation during impact, allowing the material to absorb energy through elastic and plastic deformation in a predictable manner. The curvature facilitates gradual collapse sequences that reduce peak loads while ensuring consistent energy absorption characteristics for reliable RESS protection.
2Reliability
If traditional energy absorbers are used in side impact events, then the structure provides basic energy absorption, but the intrusion distance into the RESS protection zone is excessive
Solution Approach 1:
The energy absorber is divided into multiple identical cells arranged in series along its length. Each cell contains a geometric pattern of struts that deform independently during impact, creating multiple progressive collapse zones. This segmentation allows the total impact energy to be distributed across multiple smaller deformation events rather than one large peak load, reducing the maximum force transmitted to the RESS while maintaining reliable energy absorption.
Solution Approach 2:
The geometric parameters of the struts (such as cross-sectional shape, wall thickness, and curvature radius) are specifically optimized to control the deformation sequence and energy absorption characteristics. By adjusting these parameters, the absorber is designed to achieve a target intrusion distance that provides adequate protection to the RESS while minimizing the space occupied within the rocker section.
3Force
If composite materials with reinforcing fibers are used in the energy absorber, then the energy absorption efficiency and peak load reduction are improved, but the manufacturing complexity increases
Solution Approach 1:
The energy absorber is constructed from composite materials consisting of reinforcing fibers (such as carbon, glass, or basalt fibers) embedded in a polymer matrix. This composite structure provides high strength-to-weight ratio and controlled deformation characteristics, enabling effective peak load reduction and energy absorption. The geometric pattern of struts is designed to leverage the anisotropic properties of composite materials, optimizing force distribution along the fiber directions while maintaining manufacturability through established composite fabrication processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite energy absorber effectively reduces peak loads and intrusion distances by up to 50% compared to traditional designs, enhancing passenger safety and protecting the RESS from localized high forces.
Implementation Method 1
a composite energy absorber with a geometric pattern made of reinforcing fibers and polymer matrix, integrated into the rocker section and RESS rail, which absorbs energy by crushing uniformly along its length
Data Source
AI summary
An energy absorbing system includes a structural member and a composite energy absorber including a first member arranged within the structural member. The first member has a first repeating geometric pattern extending in a first direction along a first length, a first width in a second direction transverse to the first direction, and a first height in a third direction transverse to the first and second directions. The first member is made of a composite material including first reinforcing fibers and a first polymer matrix.